Exhaust purifier and method

ABSTRACT

Catalysts in the form of very fine powder are broken from large particles of catalytic material and directed into the exhaust manifold of internal combustion engines at the region of highest temperature to purify the products of combustion.

United States Patent Schischkow Apr. 2, 1974 [54] EXHAUST PURIFIER ANDMETHOD R25,858 9/1965 Matvay 60/295 [76] Inve to onsmn F- Schischko15441 3,224,188 12/1965 Barlow 60/295 9th Ave., Whitestone, N.Y. 11357FOREIGN PATENTS OR APPLICATIONS 22 Filed: 8, 1973 942,055 11/1963 GreatBritain 60/295 [21] 330594 Primary ExaminerDouglas Hart Attorney, Agent,or FirmAlbert F. Kronman [52] US. Cl. 60/274, 23/288 F, 60/295,

60/299, 423/212 57 ABSTRACT [51] Int. Cl. F0ln 3/14 1 58 Field of Search60/274, 295, 299; Catalysts in the form of y fine Powder are broken 2323 23 25 2 from large particles of catalytic material and directed intothe exhaust manifold of internal combustion en- 5 References Cied ginesat the region of highest temperature to purify the UNITED STATES PATENTSproducts of combustion.

2,071,119 2/1937 Harger 60/295 11 Claims, 2 Drawing Figures ix/Muffk/A'f EXHAUST PURIFIER AND METHOD BACKGROUND OF THE INVENTION It iswell-known to introduce catalytic material into the exhaust manifold ofinternal combustion engines for the purpose of reducing the toxicity ofexhaust gases. Such prior art devices, however, are highly complicatedand require heating elements to bring the catalytic materials up to thedesired operating temperature,

metering valves to insure that the proper amount of catalyst is fed intothe manifold at each speed of the engine, and in some cases a series ofbaffles, vanes and other apparatus.

Other prior art devices direct catalysts into the engine cylinders orprovide chambers within the engine muffler to receive catalytic materialfor mixture with the products of combustion.

It is an object of the present invention to provide a highly simplifiedexhaust purifier for internal combustion engines.

Another object of the present invention is to provide an exhaustpurifier for internal combustion engines which can readily be attachedto existing engines without major structural changes.

A further object of the present invention is to provide an exhaustpurifier which can be serviced by relatively unskilled persons.

SUMMARY OF THE DISCLOSURE In one preferred embodiment of the presentinvention a container is secured directly to the outside of an internalcombustion engine in such manner that vibration of the engine will shakethe container. A quantity of catalytic material in the form of discreteparticles is placed within the container. A tube is led from theinterior of the container into the engine exhaust manifold at the regionof maximum temperature. The vibration of the container causes thecatalytic material to form a fine dust which is pulled into the exhaustmanifold through the tube by the pulsing pressures set up in the exhaustmanifold by the operation of the engine.

DESCRIPTION OF THE DRAWING In the accompanying drawing forming parthereof identical parts have been given the same reference numetals inwhich drawings:

FIG. 1 is a view in side elevation, partly cut away, of a portion of aninternal combustion engine with an exhaust purifier made in accordancewith the present invention attached thereto.

FIG. 2 is a vertical sectional view of a second embodiment of an exhaustpurifier according to the present invention.

GENERAL DESCRIPTION Referring to the drawing, and particularly to FIG.I, the reference numeral indicates an internal combustion engine such asa gasoline or diesel engine. An exhaust manifold 11 is provided withbranches 12 to receive the products of combustion from each of thecylinders. A central conduit 13 on the exhaust manifold directs all ofthe products of combustion from the exhaust manifold into a muffler (notshown) following which they are discharged into the atmosphere.

A container 14, made of metal or any other material which will withstandhigh temperatures is secured directly to the internal combustion engineby a bracket 15. Since most internal combustion engines, such asautomobile engines are supported by flexible mounts substantialvibration will be imparted to the container during the operation of theengine.

The container is provided with a cover 16 for easy access to itsinterior. A quantity of catalytic material 17 may thus be placed withinthe container 14 and replaced as needed during the regular servicing ofthe engine. The bottom 18 of the container 14 may include a thindiaphragm 19 to aid in agitating the catalytic material and therebypromote abrasion of the said catalytic material to produce dust-sizedparticles of catalyst.

A thin tube 20 of metal or some other high temperature resistantmaterial, is led from the interior of the container 14 to the interiorof the central conduit 13 on the exhaust manifold 11. The tube 20 isconnected to the central conduit where the said conduit joins theexhaust manifold as indicated at 21 in FIG. 1. In this manner catalyticmaterial in the form of dust 22 coming from the container 14 through thetube 20 will mix with the products of combustion at the highesttemperature which is easily available in the manifold 11. The hightemperatures are extremely important for good catalytic action in mostof the well-known catalysts. In addition the problem of good exhaustpurification when the engine is cold is overcome without the need forauxiliary sources of heat.

It has been found that the pulsing pressures set up in the exhaustmanifold of internal combustion engines, indicated by the square wave 23in FIG. I, are sufficient to draw the dust like catalyst particles 22from the container 14 into the central conduit 13 without need forspecial pumps, metering valves or the like. In order to prevent oil, tarand other products of combustion from being forced into the tube 20 asmall flap valve 20a is placed in the tube 20 between the container 14and the central conduit 13. Catalyst particles are thus kept in a dry,dust-like condition.

To aid in driving the small catalyst particles 22 to the top of thecontainer 14 where they can be drawn into the tube 20, a second tube 25is led into the container 14 near the bottom thereof. The tube 25 isattached'to a source of gas under pressure, which may be the conduit 13down stream of the tube connection at 21. A valve 26 is placed in thetube 25 to regulate the flow of gas entering the container 14 andprevent contamination of the catalytic particles.

Since a cold engine or one which is not firing properly vibrates morethan a warm engine or a properly functioning engine, a greater amount ofcatalyst abrasion takes place and more catalytic dust is produced andsucked into the conduit 13. The rough action of an engine whichcoincides with an increase in the production of pollutants thusautomatically increases the amount of catalyst being mixed with theproducts of combustion.

The specific chemical nature of the catalytic material employed in thepresent invention will vary depending upon the pollutants which are tobe suppressed. Wellknown catalytic materials may be used providing theyare dry, particulate and will abrade into a fine dust. In some instancesit may be desireable to form ceramic particles containing the catalyticmaterial to control the rate of dusting. Catalytic particles in the formof a very fine dust are suitable for the present invention. In thewell-known automobile engine using leaded fuel,

the catalyst may be selected from a wide selection of available activecatalysts as for example:

A composite of mangano-chromia-manganite catalyst having a Mn-Cr ratioof 3:0.5 to 3:1.5 which oxidizes carbon dioxide mixed withmangano-chromiamanganite catalyst having a MnCr ratio of 3:3.5 to 3:30which oxidized hydrocarbon is particularly suitable. Oxides ofmultivalent metals, such as iron, chromium, copper cobalt, manganese,molybdenum, nickel platinum and palladium are also effective. These maybe coated on base particles of pure silica or pure alumina to dust offan abrasion.

Another preferred catalyst is 9% ferric oxide promoted with 4% ofchromium oxide and 3% copper oxide. Many of the catalysts falling withinthe above enumeration are commercially available. Among these are Celite408 (Johns Manville Co. which consists of 12% ferric oxide, 6% chromiumoxide and 3% copper oxide, and Gridler G43 catalyst sold by the CatalystDivision of Chemetron Corporation, Louisville, Kentucky, which consistsof 0. 1% platinum, 3% nickel, balance alumina.

Also effective are water gas shift reaction catalysts containing about8% chromium oxide, 92% ferric oxide and town gas catalysts containing20-30% nickel on alumina promoted with a small amount of alkali oralkaline, earth metal oxides.

Similarly, zealites designated type A, X,and Y by the Linde Division ofUnion Carbide will give satisfactory results.

The precise amount of catalyst to be used will vary with the compositionof the fuels to be used, the hp. of the engine and its precise type,internal combustion or Wankel.

However, other suitable catalytic materials will suggest themselves tothose skilled in the art.

Referring to FIG. 2 there is shown a second embodiment of the presentinvention for use where it is not convenient to secure the container 14to the engine 10. This embodiment is useful where the engine does notproduce enough vibration to cause the formation of catalytic dust. Inthis form of the invention, a vibrator 24 is secured to the bottom 18 ofthe container 14. The precise nature of the vibrator forms no part ofthe present invention and may be selected from any one of the well-knownmotor driven, solenoid driven or other devices suitable for thispurpose.

Since the container of FIG. 2 does not have to be attached to the engineit can be mounted within the vehicle with the tube 20 being led into theengine compartment. This type of mounting permits the use of transparentplastic material for the container 14 so that the quantity of catalystwithin the container 14 may be checked frequently without opening theengine compartment or stopping the vehicle.

From the foregoing it will be seen that there has been provided asimplified, trouble-free exhaust purifier for internal combustionengines. The exhaust purifier is inexpensive and can be applied to newas well as in use engines with a minimum of difficulty. The rate ofcatalyst application is controlled by the performance of the enginewithout need for expensive sensing devices.

Having thus fully described the invention what is claimed and sought tobe protected by letters patent is the following:

1. A purifier for the products of combustion coming from an enginecomprising in combination with an engine having an exhaust manifold, acontainer, a quantity of catalytic material in dry form within thecontainer, a first tube leading from the interior of the container tothe interior of the exhaust manifold, a second tube in communicationwith the interior of the container, a source of gas under pressureconnected to the second tube and means to vibrate the container toabrade the catalyst therein to form a fine dust of catalytic particles,whereby the catalytic particles in dust form will be drawn into andreact with the products of combustion passing through the exhaustmanifold.

2. A purifier according to claim 1 in which the first tube is led intothe container at the upper portion thereof, the second tube is led intothe container at the lower portion thereof and the means to vibrate thecontainer includes a bracket secured to the container and the engine.

3. A purifier according to claim 1 in which a valve is incorporated inthe first tube between the container and the engine manifold.

4. A purifier according to claim 1 in which the engine exhaust manifoldincludes a conduit into which all the products of combustion from aplurality of cylinders is led and the first tube is connected to theconduit in close proximity to the area where the conduit joins theexhaust manifold.

5. A purifier according to claim 3 in which the valve is a flap valvewhereby the products of combustion coming from the engine cannot enterthe container.

6. A purifier according to claim 5 in which a valve is incorporated inthe second tube between the source of gas under pressure and thecontainer.

7. A purifier according to claim 6 in which the source of gas underpressure is the exhaust manifold.

8. A purifier according to claim 1 in which the vibrating means includesa diaphragm in the bottom of the container.

9. A purifier according to claim 1 in which the vibrating means is avibrator secured to the container.

10. The method of purifying the products of combustion coming from anengine comprising the steps of placing a quantity of a catalyticmaterial within a container, vibrating the container to abrade thecatalytic material to form a fine dust of said material, directing thesaid dust into the exhaust manifold of an engine in an area of maximumtemperature of the products of combustion therein whereby the cataliticmaterial reacts with the said products of combustion to render themnon-toxic.

11. The method according to claim 10 in which gas under pressure isintroduced into the container.

2. A purifier according to claim 1 in which the first tube is led into the container at the upper portion thereof, the second tube is led into the container at the lower portion thereof and the means to vibrate the container includes a bracket secured to the container and the engine.
 3. A purifier according to claim 1 in which a valve is incorporated in the first tube between the container and the engine manifold.
 4. A purifier according to claim 1 in which the engine exhaust manifold includes a conduit into which all the products of combustion from a plurality of cylinders is led and the first tube is connected to the conduit in close proximity to the area where the conduit joins the exhaust manifold.
 5. A purifier according to claim 3 in which the valve is a flap valve whereby the products of combustion coming from the engine cannot enter the container.
 6. A purifier according to claim 5 in which a valve is incorporated in the second tube between the source of gas under pressure and the container.
 7. A purifier according to claim 6 in which the source of gas under pressure is the exhaust manifold.
 8. A purifier according to claim 1 in which the vibrating means includes a diaphragm in the bottom of the container.
 9. A purifier according to claim 1 in which the vibrating means is a vibrator secured to the container.
 10. The method of purifying the products of combustion coming from an engine comprising the steps of placing a quantity of a catalytic material within a container, vibrating the container to abrade the catalytic material to form a fine dust of said material, directing the said dust into the exhaust manifold of an engine in an area of maximum temperature of the products of combustion therein whereby the catalitic material reacts with the said products of combustion to render them non-toxic.
 11. The method according to claim 10 in which gas under pressure is introduced into the container. 